U.S. patent application number 14/042210 was filed with the patent office on 2014-06-12 for waved filter media and elements.
This patent application is currently assigned to Hollingsworth & Vose Company. The applicant listed for this patent is Hollingsworth & Vose Company. Invention is credited to Richard Gahan, David T. Healey.
Application Number | 20140157742 14/042210 |
Document ID | / |
Family ID | 39714337 |
Filed Date | 2014-06-12 |
United States Patent
Application |
20140157742 |
Kind Code |
A1 |
Healey; David T. ; et
al. |
June 12, 2014 |
WAVED FILTER MEDIA AND ELEMENTS
Abstract
Various high performance, high efficiency filter media are
provided that are cost effective and easy to manufacture. In
particular, various filter media are provided having at least one
layer with a waved configuration that results in an increased
surface area, thereby enhancing various properties of the filter
media. The filter media can be used to form a variety of filter
elements for use in various applications.
Inventors: |
Healey; David T.;
(Bellingham, MA) ; Gahan; Richard; (Wrentham,
MA) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
Hollingsworth & Vose Company |
East Walpole |
MA |
US |
|
|
Assignee: |
Hollingsworth & Vose
Company
East Walpole
MA
|
Family ID: |
39714337 |
Appl. No.: |
14/042210 |
Filed: |
September 30, 2013 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
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13462420 |
May 2, 2012 |
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14042210 |
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12982103 |
Dec 30, 2010 |
8197569 |
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13462420 |
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12038049 |
Feb 27, 2008 |
7883562 |
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12982103 |
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60892025 |
Feb 28, 2007 |
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60986626 |
Nov 9, 2007 |
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Current U.S.
Class: |
55/514 |
Current CPC
Class: |
B01D 2239/0233 20130101;
B01D 46/522 20130101; B01D 39/163 20130101; B01D 2239/1258
20130101; B01D 39/1623 20130101; B01D 2239/1291 20130101; B01D
2275/10 20130101; B01D 39/2017 20130101; B01D 46/16 20130101; B01D
46/521 20130101; B01D 2239/0654 20130101; B01D 2239/0225 20130101;
B01D 46/523 20130101 |
Class at
Publication: |
55/514 |
International
Class: |
B01D 46/16 20060101
B01D046/16 |
Claims
1. (canceled)
2. A filter media, comprising: a filtration layer comprising a
plurality of waves having peaks and troughs in a waved
configuration, the filter media further comprising: means for
holding the filtration layer in the waved configuration; means for
maintaining separation of the peaks and troughs of adjacent waves
of the filtration layer; means for achieving an overall air
permeability in the range of 10-300 CFM; means for achieving a DOP
filtration efficiency in the range of about 20% to 99%; and means
for achieving a dust holding capacity of at least 8 g/ft.sup.2.
3. The filter media of claim 2, wherein the filter media has an
overall thickness in the range of about 1.5 mm to 25 mm and an
overall basis weight of between 70-1100 gsm.
4. The filter media of claim 2, further comprising means for
achieving a MERV rating in the range of 7 to 16.
5. The filter media of claim 2, further comprising means for
achieving a DOP filtration efficiency in the range of about 20% to
99%.
6. The filter media of claim 2, further comprising means for
achieving an overall pressure drop in the range of about 0.1'' to
1'' inch H2O.
7. The filter media of claim 2, further comprising means for
achieving a DOP alpha value in the range of 12-16.
Description
CROSS REFERENCE TO RELATED APPLICATIONS
[0001] The present application is a continuation of U.S.
application Ser. No. 13/462,420, filed May 2, 2012, which is a
continuation of U.S. application Ser. No. 12/982,103 (now U.S. Pat.
No. 8,197,569), filed Dec. 30, 2010, which is a continuation of
U.S. application Ser. No. 12/038,049 (now U.S. Pat. No. 7,883,562),
filed on Feb. 27, 2008, which claims priority to U.S. Provisional
Application No. 60/986,626 filed on Nov. 9, 2007 and U.S.
Provisional Application No. 60/892,025 filed on Feb. 28, 2007. All
of these applications are hereby incorporated by reference in their
entireties.
FIELD OF THE INVENTION
[0002] The present invention relates to filtration, and more
particularly to high capacity filter media and elements.
BACKGROUND OF THE INVENTION
[0003] The removal of air borne particulate contaminants from the
air is a concern to everyone. Gas phase particulate filtration has
traditionally been accomplished by methods that utilize woven or
nonwoven fabrics or webs. The performance of such a system is
characterized by the initial efficiency of removal or capture of
the particulate as a function of particle size, the initial
resistance of the system to air or gas flow as a function of gas
flow rate or face velocity, and the way both of these factors
change as the filter element loads with the particulate
contaminant. One common measurement is the alpha value of a media,
which is the product of the pressure drop and the filtration
efficiency, and is calculated as follows:
alpha=-100*log((100-efficiency)/100)/Pressure Drop.
[0004] Generally, it is desirable that a particular filter media
have a higher alpha value, as this is indicative that media has a
low pressure drop and a high efficiency. For example, the glass
materials that are used for ASHRAE bag filters have alpha values
(obtained with a DOP challenge) that are in the range of 12-16
(depending upon the particular efficiency of the media), and are
not reliant on any type of electrostatic charge to achieve this
alpha value. Glass paper can have alpha values of about 12-13,
membrane materials can have alpha values of about 20, and nanofiber
electrospun materials can have alpha values in the range of about
5-12. None of these materials is reliant on any type of
electrostatic charge to achieve these alpha values.
[0005] Filtration media formed from using meltblown, spunbond,
carded nonwoven, and wet laid synthetic materials can have very
high alpha values when they are electrostatically charged. However,
when the charge is removed, the alpha values of these media
significantly decreases to levels that are well below the alpha
values of media made using other materials.
[0006] Accordingly, there remains a need to provide an improved
filter, and more particularly to provide filter media and filter
elements having improved discharged alpha value.
SUMMARY OF THE INVENTION
[0007] In one embodiment, a filter media is provided having a fine
fiber filtration layer and a coarse support layer that holds the
fine fiber filtration layer in a waved configuration and maintains
separation of peaks and troughs of adjacent waves of the filtration
layer. The layers of the filter media, as well as the various
properties of each layer can vary. In one embodiment, the coarse
support layer has a density that is greater at the peaks than a
density in the troughs. In another embodiment, the fine fiber
filtration layer can have a surface area that is at least 50%, and
more preferably 100%, greater than a surface area of the fine fiber
filtration layer in a planar configuration. In another embodiment,
the coarse support layer can be a downstream coarse support layer,
and the filter media can further include an upstream coarse support
layer. The fine fiber filtration layer can be disposed between the
upstream coarse support layer and the downstream coarse support
layer. The filter media can also include at least one additional
filtration layer disposed between the downstream coarse support
layer and the upstream coarse support layer. In one exemplary
embodiment, the at least one additional filtration layer can be
formed from fibers having an average diameter greater than an
average fiber diameter of fibers that form the fine fiber
filtration layer.
[0008] The fiber diameters of the various layers can vary. In one
embodiment, the upstream coarse support layer can be formed from
fibers having an average diameter greater than an average diameter
of fibers forming the fine fiber filtration layer and equal to or
less than an average diameter of fibers forming the downstream
coarse support layer. In an exemplary embodiment, the upstream
coarse support layer, the fine fiber filtration layer, and the
downstream coarse support layer all have a waved configuration. In
an exemplary embodiment, the filter media has about 2 to 6 waves
per inch. The upstream and downstream coarse support layers can be
formed from, for example, staple fiber layers, and the fine fiber
filtration layer can be at least one of a meltblown layer and a
glass fiber layer. The coarse support layer can also be formed from
at least one binder fiber and at least one non-binder fiber.
[0009] In another embodiment, the filter media can include at least
one of a planar layer disposed upstream of the upstream coarse
support layer and a planar layer disposed downstream of the
downstream coarse support layer. The planar layer can be formed
from fibers having an average diameter less than an average
diameter of fibers forming the upstream coarse support layer and
the downstream coarse support layer, and greater than an average
diameter of fibers forming the fine fiber filtration layer. In
another embodiment, the planar layer can be formed from fibers
having an average diameter that is greater than the upstream and
downstream coarse support layers and the fine fiber filtration
layer. In such an embodiment, the planar layer is preferably
disposed downstream of the downstream coarse support layer.
[0010] The filter media can also have various properties. For
example, the filter media can have a DOP alpha value of greater
than about 9, and more preferably greater than about 11; a dust
holding capacity of at least about 8 g/ft.sup.2 at 25 FPM face
velocity using ASHRAE dust loading to 1.5 inch H.sub.2O pressure
drop; a NaCl loading of less than about 50 mm H.sub.2O after
loading approximately 60 mg/100 cm.sup.2 of 0.26.mu. particles at
25 FPM face velocity; an air permeability in the range of about 10
CFM to 300 CFM; a basis weight in the range of about 70 gsm to 1100
gsm; and/or a thickness in the range of about 1.5 mm to 25 mm.
[0011] In yet another embodiment, a filter media is provided having
a first fibrous layer with a waved configuration forming a
plurality of waves, each wave having a random wave form and height,
and each wave having a peak and a trough, adjacent peaks being
spaced a distance apart from one another and adjacent troughs being
spaced a distance apart from one another. The filter media can also
include a second fibrous layer mated to the first fibrous layer and
formed from fibers that are more coarse than fibers forming the
first layer.
[0012] In one embodiment, the first fibrous layer can have a
surface area that is at least about 50% greater, and more
preferably 100% greater, than a surface area of the first fibrous
layer in a planar configuration. The first fibrous layer can be
formed from, for example, fine fibers having an average diameter
less than an average diameter of fibers forming the second fibrous
layer. The average diameter of the fibers of the first fibrous
layer can be less than about 5.mu. and the average diameter of the
fibers of the second fibrous layer is greater than about 10. In
another embodiment, the second fibrous layer can have a fiber
density that is greater adjacent to the peaks of the first fibrous
layer than the fiber density adjacent to the troughs of the first
fibrous layer. The second fibrous layer can be disposed downstream
of the first fibrous layer, and the filter media can also include a
third fibrous layer disposed upstream of the first fibrous layer.
In one exemplary embodiment, the third fibrous layer is formed from
fibers having an average diameter that is equal to or less than an
average diameter of fibers forming the second fibrous layer, and
the diameter of the fibers forming the second fibrous layer is
greater than an average diameter of fibers forming the first
fibrous layer. The first, second, and third fibrous layers can have
a waved configuration, and the filter media can also include at
least one of a fourth layer disposed upstream of the third fibrous
layer and having a planar configuration and a fifth layer disposed
downstream of the second fibrous layer and having a planar
configuration. In certain exemplary embodiments, the first fibrous
layer is a meltblown layer or a glass fiber layer, and the second
fibrous layer is formed from at least one binder fiber and at least
one non-binder fiber.
[0013] In yet another embodiment, a multi-layer filter media is
provided having a curvilinear web formed from a fine fiber layer
and at least one coarse support layer formed from a blend of binder
fibers and non-binder fibers. The at least one coarse support layer
can maintain spacing between adjacent peaks of the fine fiber layer
and maintain spacing between adjacent troughs of the fine fiber
layer. The filter media can also include a planar web mated to the
curvilinear web.
[0014] In one embodiment, the fine fiber layer can be a meltblown
layer or a glass layer, and the at least one coarse support layer
can be formed from at least one binder fiber and at least one
non-binder fiber. The at least one coarse support layer can include
a first coarse support layer disposed upstream of the fine fiber
layer and a second coarse support layer disposed downstream of the
fine fiber layer. The planar web can be disposed upstream of the
first coarse support layer. In an exemplary embodiment, the second
coarse support layer is formed from fibers having an average fiber
diameter that is greater than an average fiber diameter of fibers
forming the first coarse support layer, and the average fiber
diameter of the fibers forming the second coarse support layer is
greater than an average fiber diameter of the fibers forming planar
web, and the average fiber diameter of the fibers forming the
planar web is greater than an average fiber diameter of fibers
forming the fine fiber layer. In other aspects, the fine fiber
layer can have a surface area that is at least about 50% greater
than a surface area of the fine fiber layer in a planar
configuration.
[0015] In other aspects, a filter element is provided having a
filter media with at least two fibrous layers having a waved
configuration such that the filter media includes a plurality of
non-uniform waves having a height that is about 2'' or less. At
least one of the fibrous layers can be a fine fiber filtration
layer, such as a meltblown layer or a glass layer, and at least one
of the fibrous layers can be a coarse fiber support layer. The
filter element can also include a housing disposed around a
perimeter of the filter media. In one embodiment, the housing can
be formed by stiffening a portion of the perimeter of the filter
media. In another embodiment, the housing can be a frame disposed
around the perimeter of the filter media. The filter media
preferably has a MERV rating of 7 to 16.
[0016] In another embodiment, a pleated filter element is provided
having a filtration layer and a support layer mated together to
form a waved filter media with a plurality of peaks and troughs.
The waved filter media is pleated. In an exemplary embodiment, the
waved filter media includes a stiff backing sufficient to allow the
waved filter media to maintain pleats. Alternatively or in
addition, the waved filter media can have a stiffness that allows
the waved filter media to maintain pleats. In an exemplary
embodiment, the waved filter media has a thickness, before
pleating, of about 0.5'' or less, and a thickness when pleated of
about 12'' or less, and more preferably about 2'' or less. The
pleated waved filter media can also include a housing disposed
around a perimeter of the filter media. In an exemplary embodiment,
the pleated filter media has MERV rating of 7 to 16.
[0017] In other aspects, a bag filter is provided having a housing
and a plurality of filters mated to the housing. Each filter can
have a pocket formed therein and can be configured to receive
airflow therethrough, and each filter can be formed from a filter
media having a first fibrous layer, such as a meltblown or glass
layer, that is held in a waved configuration by a second fibrous
layer to form peaks and troughs. The housing can be, for example, a
frame and an open end of each filter can be mated to the frame. The
filters can be positioned parallel to one another. The filters can
also optionally include at least one spacer disposed therein and
adapted to maintain opposed sidewalls of the filter at a
predetermined distance apart from one another. In an exemplary
embodiment, the filter media has a thickness that is about 2'' or
less, and more preferably about 0.5'' or less, and/or a MERV rating
in the range of about 7 to 16, and more preferably about 10 to 16.
The filter media can also include a third fibrous layer disposed on
a side of the first fibrous layer opposite to the second fibrous
layer.
BRIEF DESCRIPTION OF THE DRAWINGS
[0018] FIG. 1A is a side view illustration of one embodiment of a
filter media;
[0019] FIG. 1B is a side view illustration of another embodiment of
a filter media;
[0020] FIG. 1C is a side view illustration of one layer of the
filter media of FIG. 1A;
[0021] FIG. 2A is a perspective view of one embodiment of a panel
filter;
[0022] FIG. 2B is a side cross-sectional view of the panel filter
of FIG. 2A taken across line 2B;
[0023] FIG. 3 is a side view of another embodiment of a panel
filter;
[0024] FIG. 4A is a perspective view of one embodiment of a pleated
filter element;
[0025] FIG. 4B is a side cross-sectional view of another embodiment
of a pleated filter element;
[0026] FIG. 4C is a side cross-sectional view of yet another
embodiment of a pleated filter element;
[0027] FIG. 5A is a perspective view of one embodiment of a bag
filter having multiple filter bags disposed therein;
[0028] FIG. 5B is a perspective view of one of the filter bags of
FIG. 5A;
[0029] FIG. 5C is a side cross-sectional view of the filter bag of
FIG. 5B;
[0030] FIG. 6 is a chart showing discharged DOP penetration versus
pressure drop for various filter media;
[0031] FIG. 7 is a chart showing dust holding capacity for various
filter media;
[0032] FIG. 8 is a chart showing NaCl Loading for various filter
media; and
[0033] FIG. 9 is a chart showing a multi-pass liquid test for
various filter media.
DETAILED DESCRIPTION OF THE INVENTION
[0034] Certain exemplary embodiments will now be described to
provide an overall understanding of the principles of the
structure, function, manufacture, and use of the devices and
methods disclosed herein. Those skilled in the art will understand
that the devices and methods specifically described herein are
non-limiting exemplary embodiments and that the scope of the
present invention is defined solely by the claims. The features
described in connection with one exemplary embodiment may be
combined with the features of other embodiments. Such modifications
and variations are intended to be included within the scope of the
present invention.
[0035] The present invention generally provides various high
performance, high efficiency filter media that are cost effective
and easy to manufacture. In particular, various filter media are
provided having at least one layer with a waved configuration that
results in an increased surface area, thereby enhancing various
properties of the filter media. The filter media can be used to
form a variety of filter elements for use in various
applications.
[0036] Media
[0037] In general, various filter media are provided having at
least one fibrous layer that is held in a waved or curvilinear
configuration by one or more additional fibrous layers. As a result
of the waved configuration, the filter media has an increased
surface area which results in improved filtration properties. The
filter media can include various fibrous layers, and only some or
all of the layers can be waved. FIG. 1A illustrates one exemplary
embodiment of a filter media 10 having at least one filtration
layer and at least one coarse support layer that holds the
filtration layer in a waved configuration to maintain separation of
peaks and troughs of adjacent waves of the filtration layer. In the
illustrated embodiment, the filter media 10 includes a fine fiber
filtration layer 12, a first, downstream coarse support layer 14,
and a second, upstream coarse support layer 16 disposed on opposite
sides of the fine fiber filtration layer 12. The support layers 14,
16 can help maintain the fine fiber filtration layer 12, and
optionally any additional filtration layers, in the waved
configuration. While two coarse support layers 14, 16 are shown,
the filter media 10 need not include both support layers. Where
only one coarse support layer is provided, the coarse support layer
can be disposed upstream or downstream of the filtration
layer(s).
[0038] The filter media 10 can also optionally include one or more
outer or cover layers located on the upstream-most and/or
downstream-most sides of the filter media 10. FIG. 1A illustrates a
top layer 18 disposed on the upstream side of the filter media 10
to function as an upstream dust holding layer. The top layer 18 can
also function as an aesthetic layer, which will be discussed in
more detail below. The layers in the illustrated embodiment are
arranged so that the top layer 18 is disposed on the air entering
side, labeled I, the second coarse support layer 16 is just
downstream of the top layer 18, the fine fiber filtration layer 12
is disposed just downstream of the second coarse support layer 16,
and the first coarse support layer 14 is disposed downstream of the
first layer 12 on the air outflow side, labeled O. The direction of
air flow, i.e., from air entering I to air outflow O, is indicated
by the arrows marked with reference A.
[0039] The outer or cover layer can alternatively or additionally
be a bottom layer disposed on the downstream side of the filter
media 10 to function as a strengthening component that provides
structural integrity to the filter media 10 to help maintain the
waved configuration. The outer or cover layer(s) can also function
to offer abrasion resistance. FIG. 1B illustrates another
embodiment of a filter media 10B that is similar to filter media 10
of FIG. 1B. In this embodiment, the filter media 10B does not
include a top layer, but rather has a fine fiber filtration layer
12B, a first coarse support layer 14B disposed just downstream of
the fine fiber filtration layer 12B, a second coarse support layer
16B disposed just upstream of the fine fiber filtration layer 12B
on the air entering side I, and a bottom layer 18B disposed just
downstream of the first coarse support layer 14B on the air exiting
side O. A person skilled in the art will appreciate that a variety
of other configurations are possible, and that the filter media can
include any number of layers in various arrangements.
[0040] Fine Fiber Layer
[0041] As indicated above, in an exemplary embodiment the filter
media 10 includes at least one fine fiber filtration layer 12. In
an exemplary embodiment, a single filtration layer 12 formed from
fine fibers is used, however the filter media 10 can include any
number of additional filtration layers disposed between the
downstream coarse support layer and the upstream coarse support
layer, adjacent to the fine fiber filtration layer 12, or disposed
elsewhere within the filter media. While not shown, the additional
filtration layer(s) can be maintained in a waved configuration with
the fine fiber filtration layer 12. In certain exemplary embodiment
the filter media 10 can include one or more additional filtration
layers disposed upstream of the fine fiber filtration layer 12. The
additional filtration layer(s) can be formed from fine fibers, or
more preferably can be formed from fibers having an average fiber
diameter that is greater than an average fiber diameter of the
fibers that form the fine fiber filtration layer 12.
[0042] The fine fiber filtration layer 12 can be formed from a
variety of fibers, but in an exemplary embodiment the fine fiber
filtration layer 12 is formed from fibers having an average fiber
diameter that is less than about 10.mu., and more preferably that
is less than about 5.mu., and more preferably that is less than
about 3.mu.. In certain exemplary embodiments, the fibers can have
an average fiber diameter of about 1.5.mu. or less, including
nanofibers having an average diameter of less than about 1.mu..
[0043] If provided, any additional filtration layers can likewise
be formed from a variety of fibers, but in an exemplary embodiment
the additional filtration layer(s) is/are formed from fibers having
an average fiber diameter that is greater than about 5.mu. but
preferably that is less than about 10.mu..
[0044] Various materials can also be used to form the fibers,
including synthetic and non-synthetic materials. In one exemplary
embodiment, the fine fiber filtration layer 12, and any additional
filtration layer(s), is formed from meltblown fibers. Exemplary
materials include, by way of non-limiting example, polyolefins,
such as polypropylene and polyethylene; polyesters, such as
polybutylene terephthalate and polyethylene terephthalate;
polyamides, such as Nylon; polycarbonate; polyphenylene sulfide;
polystyrene; and polyurethane. In another embodiment, the fine
fiber filtration layer 12 can be formed from glass fibers. Various
manufacturing techniques can be used to form the glass fiber web,
include wetlaid or drylaid webs. The type and size of glass fiber
can also vary, but in an exemplary embodiment, the fiber is a
microglass fiber, such as A-type or E-type glass fibers made using
a rotary or flame attenuation process and having an average fiber
diameter in the range of about 0.2.mu., to 5.mu.. However, other
suitable materials include, by way of non-limiting example,
polyvinyl alcohol and polyvinylidene fluoride. The fine fiber
filtration layer 12, and any additional filtration layer(s), can
also be formed using various other techniques known in the art,
including wet laid techniques, air laid techniques, carding,
electrospining, and spunbonding.
[0045] The resulting fine fiber filtration layer 12, as well as any
additional filtration layer(s), can also have a variety of
thicknesses, air permeabilities, basis weights, and filtration
efficiencies depending upon the requirements of a desired
application. In one exemplary embodiment, the fine fiber filtration
layer 12, as measured in a planar configuration, has a thickness in
the range of about 2 mils to 30 mils, an air permeability in the
range of about 10 CFM to 300 CFM, a basis weight in the range of
about 3 gsm to 50 gsm, and a DOP filtration efficiency in the range
of about 20% to 99%. If any additional filtration layers are
provided, in certain exemplary embodiments each additional
filtration layer, as measured in a planar configuration, has a
thickness in the range of about 2 mils to 30 mils, an air
permeability in the range of about 10 CFM to 300 CFM, a basis
weight in the range of about 3 gsm to 50 gsm, and a DOP filtration
efficiency in the range of about 20% to 99%.
[0046] Coarse Support Layers
[0047] As also indicated above, the filter media 10 can include at
least one coarse fibrous support layer. In an exemplary embodiment,
the filter media 10 includes a downstream coarse support layer 14
disposed on the air outflow side O of the fine fiber filtration
layer 12 and that is effective to hold the fine fiber filtration
layer 12 in the waved configuration. The filter media 10 can also
include an upstream coarse support layer 16 that is disposed on the
air entering side I of the fine fiber filtration layer 12 opposite
to the downstream coarse support layer 14. The upstream coarse
support layer 16 can likewise help maintain the fine fiber
filtration layer 12 in a waved configuration. As indicated above, a
person skilled in the art will appreciate that the filter media 10
can include any number of layers, and it need not include two
coarse support layers, or a top layer. In certain exemplary
embodiments, the filter media 10 can be formed from a fine fiber
filtration layer 12 and a single, adjacent coarse support layer 14
or 16. In other embodiments, the filter media can include any
number of additional layers arranged in various configurations. The
particular number and type of layers will depend on the intended
use of the filter media.
[0048] The coarse support layers 14, 16 can be formed from a
variety of fibers types and sizes. In an exemplary embodiment, the
downstream coarse support layer 14 is formed from fibers having an
average fiber diameter that is greater than an average fiber
diameter of the fine fiber filtration layer 12, the upstream coarse
support layer 16, and the top layer 18, if provided, and the
upstream coarse support layer 16 is formed from fibers having an
average fiber diameter that is less than an average fiber diameter
of the downstream coarse support layer 14, but that is greater than
an average fiber diameter of the fine fiber filtration layer 12 and
the top layer 18. In certain exemplary embodiments, the downstream
coarse support layer 14 can be formed from fibers having an average
fiber diameter in the range of about 5.mu. to 40.mu., and more
preferably that is in the range of about 20.mu. to 30.mu., and the
upstream coarse support layer 16 can be formed from fibers having
an average fiber diameter that is in the range of about 10.mu. to
40.mu., and more preferably that is in the range of about 15.mu. to
20.mu..
[0049] Various materials can also be used to form the fibers of the
coarse support layers 14, 16, including synthetic and non-synthetic
materials. In one exemplary embodiment, the coarse support layers
14, 16 are formed from staple fibers, and in particular from a
combination of binder fibers and non-binder fibers. One suitable
fiber composition is a blend of at least about 20% binder fiber and
a balance of non-binder fiber. A variety of types of binder and
non-binder fibers can be used to form the media of the present
invention. The binder fibers can be formed from any material that
is effective to facilitate thermal bonding between the layers, and
will thus have an activation temperature that is lower than the
melting temperature of the non-binder fibers. The binder fibers can
be monocomponent fibers or any one of a number of bicomponent
binder fibers. In one embodiment, the binder fibers can be
bicomponent fibers, and each component can have a different melting
temperature. For example, the binder fibers can include a core and
a sheath where the activation temperature of the sheath is lower
than the melting temperature of the core. This allows the sheath to
melt prior to the core, such that the sheath binds to other fibers
in the layer, while the core maintains its structural integrity.
This is particularly advantageous in that it creates a more
cohesive layer for trapping filtrate. The core/sheath binder fibers
can be concentric or non-concentric, and exemplary core/sheath
binder fibers can include the following: a polyester
core/copolyester sheath, a polyester core/polyethylene sheath, a
polyester core/polypropylene sheath, a polypropylene
core/polyethylene sheath, and combinations thereof. Other exemplary
bicomponent binder fibers can include split fiber fibers,
side-by-side fibers, and/or "island in the sea" fibers. Exemplary
bi-component binder fibers can include Trevira Types 254, 255, and
256; Invista Cellbond.RTM. Type 255; Fiber Innovations Types 201,
202, 215, and 252; and ES Fibervisions AL-Adhesion-C ESC 806A.
[0050] The non-binder fibers can be synthetic and/or non-synthetic,
and in an exemplary embodiment the non-binder fibers can be about
100 percent synthetic. In general, synthetic fibers are preferred
over non-synthetic fibers for resistance to moisture, heat,
long-term aging, and microbiological degradation. Exemplary
synthetic non-binder fibers can include polyesters, acrylics,
polyolefins, nylons, rayons, and combinations thereof.
Alternatively, the non-binder fibers used to form the media can
include non-synthetic fibers such as glass fibers, glass wool
fibers, cellulose pulp fibers, such as wood pulp fibers, and
combinations thereof. Exemplary synthetic non-binder fibers can
include Trevira Type 290 and Wellman Fortrel.RTM. Types 204, 289
and 510.
[0051] The coarse support layers 14, 16 can also be formed using
various techniques known in the art, including meltblowing, wet
laid techniques, air laid techniques, carding, electrospining, and
spunbonding. In an exemplary embodiment, however, the coarse
support layers 14, 16 are carded or airlaid webs. The resulting
layers 14, 16 can also have a variety of thicknesses, air
permeabilities, and basis weights depending upon the requirements
of a desired application. In one exemplary embodiment, the
downstream coarse support layer 14 and the upstream coarse support
layer 16, as measured in a planar configuration, each have a
thickness in the range of about 10 mil to 60 mil, an air
permeability in the range of about 300 CFM to 1000 CFM, and a basis
weight in the range of about 10 gsm to 100 gsm.
[0052] Outer or Cover Layer
[0053] As previously indicated, the filter media 10 can also
optionally include one or more outer or cover layers disposed on
the air entering side I and/or the air outflow side O. FIG. 1A
illustrates a top layer 18 disposed on the air entering side I of
the filter media 10. The top layer 18 can function as a dust
loading layer and/or it can function as an aesthetic layer. In an
exemplary embodiment, the top layer 18 is a planar layer that is
mated to the filter media 10 after the fine fiber filtration layer
12 and the coarse support layers 14, 16 are waved. The top layer 18
thus provides a top surface that is aesthetically pleasing. The top
layer 18 can be formed from a variety of fiber types and sizes, but
in an exemplary embodiment the top layer 18 is formed from fibers
having an average fiber diameter that is less than an average fiber
diameter of the upstream coarse support layer 16 disposed
immediately downstream of the top layer 18, but that is greater
than an average fiber diameter of the fine fiber filtration layer
12. In certain exemplary embodiments, the top layer 18 is formed
from fibers having an average fiber diameter in the range of about
5.mu. to 20.mu.. As a result, the top layer 18 can function as a
dust holding layer without affecting the alpha value of the filter
media 10, as will be discussed in more detail below.
[0054] As shown in FIG. 1B, the filter media 10B can alternatively
or in addition include a bottom layer 18B disposed on the air
outflow side O of the filter media 10B. The bottom layer 18B can
function as strengthening component that provides structural
integrity to the filter media 10B to help maintain the waved
configuration. The bottom layer 18B can also function to offer
abrasion resistance. This is particularly desirable in ASHRAE bag
applications where the outermost layer is subject to abrasion
during use. The bottom layer 18B can have a configuration similar
to the top layer 18, as discussed above. In an exemplary
embodiment, however, the bottom layer 18B is preferably the
coarsest layer, i.e., it is formed from fibers having an average
fiber diameter that is greater than an average fiber diameter of
fibers forming all of the other layers of the filter media. One
exemplary bottom layer is a spunbond layer, however various other
layers can be used having various configurations.
[0055] Various materials can also be used to form the fibers of the
outer or cover layer, including synthetic and non-synthetic
materials. In one exemplary embodiment, the outer or cover layer,
e.g., top layer 18 and/or bottom layer 18B, is formed from staple
fibers, and in particular from a combination of binder fibers and
non-binder fibers. One suitable fiber composition is a blend of at
least about 20% binder fiber and a balance of non-binder fiber. A
variety of types of binder and non-binder fibers can be used to
form the media of the present invention, including those previously
discussed above with respect to the coarse support layers 14,
16.
[0056] The outer or cover layer, e.g., top layer 18 and/or any
bottom layer, can also be formed using various techniques known in
the art, including meltblowing, wet laid techniques, air laid
techniques, carding, electrospining, and spunbonding. In an
exemplary embodiment, however, the top layer 18 is an airlaid layer
and the bottom layer 18B is a spunbond layer. The resulting layer
can also have a variety of thicknesses, air permeabilities, and
basis weights depending upon the requirements of a desired
application. In one exemplary embodiment, the outer or cover layer,
as measured in a planar configuration, has a thickness in the range
of about 2 mil to 50 mil, an air permeability in the range of about
100 CFM to 1200 CFM, and a basis weight in the range of about 10
gsm to 50 gsm.
[0057] A person skilled in the art will appreciate that, while FIG.
1A illustrates a four layer filter media, the media can include any
number of layers in various configurations. Various layers can be
added to enhance filtration, to provide support, to alter
structure, or for various other purposes. By way of non-limiting
example, the filter media can include various spunbond wetlaid
cellulose, drylaid synthetic nonwoven, wetlaid synthetic, and
wetlaid microglass layers.
[0058] Method of Manufacturing
[0059] Some or all of the layers can be formed into a waved
configuration using various manufacturing techniques, but in an
exemplary embodiment the fine fiber filtration layer 12, any
additional filtration layers, and preferably at least one of the
coarse support layers 14, 16, are positioned adjacent to one
another in a desired arrangement from air entering side to air
outflow side, and the combined layers are conveyed between first
and second moving surfaces that are traveling at different speeds,
such as with the second surface traveling at a speed that is slower
than the speed of the first surface. A suction force, such as a
vacuum force, can be used to pull the layers toward the first
moving surface, and then toward the second moving surface as the
layers travel from the first to the second moving surfaces. The
speed difference causes the layers to form z-direction waves as
they pass onto the second moving surface, thus forming peaks and
troughs in the layers. The speed of each surface can be altered to
obtain the desired number of waves per inch. The distance between
the surfaces can also be altered to determine the amplitude of the
peaks and troughs, and in an exemplary embodiment the distance is
adjusted between 0 to 2''. The properties of the different layers
can also be altered to obtain a desired filter media configuration.
In an exemplary embodiment the filter media has about 2 to 6 waves
per inch, with a height (overall thickness) in the range of about
0.025'' to 2'', however this can vary significantly depending on
the intended application. As shown in FIG. 1A, a single wave W
extends from the middle of one peak to the middle of an adjacent
peak
[0060] In the embodiment shown in FIG. 1A, when the fine fiber
filtration layer 12 and the coarse support layers 14, 16 are waved,
the resulting fine fiber filtration layer 12 will have a plurality
of peaks P and troughs T on each surface (i.e., air entering side I
and air outflow side O) thereof, as shown in FIG. 1C. The coarse
support layers 14, 16 will extend across the peaks P and into the
troughs T so that the coarse support layers 14, 16 also have waved
configurations. A person skilled in the art will appreciate that a
peak P on the air entering side I of the fine fiber filtration
layer 12 will have a corresponding trough T on the air outflow side
O. Thus, the downstream coarse support layer 14 will extend into a
trough T, and exactly opposite that same trough T is a peak P,
across which the upstream coarse support layer 16 will extend.
Since the downstream coarse support layer 14 extends into the
troughs T on the air outflow side O of the fine fiber filtration
layer 12, the downstream coarse layer 14 will maintain adjacent
peaks P on the air outflow side O at a distance apart from one
another and will maintain adjacent troughs T on the air outflow
side O at a distance apart from one another. The upstream coarse
support layer 16, if provided, can likewise maintain adjacent peaks
P on the air entering side I of the fine fiber filtration layer 12
at a distance apart from one another and can maintain adjacent
troughs T on the air entry side I of the fine fiber filtration
layer 12 at a distance apart from one another. As a result, the
fine fiber filtration layer 12 has a surface area that is
significantly increased, as compared to a surface area of the fine
fiber filtration layer in the planar configuration. In certain
exemplary embodiments, the surface area in the waved configuration
is increased by at least about 50%, and in some instances as much
as 120%, as compared to the surface area of the same layer in a
planar configuration. The increased surface area leads to an
increased filtration efficiency, as will be discussed in more
detail below.
[0061] In certain exemplary embodiments, the downstream and/or
upstream coarse support layers 14, 16 can have a fiber density that
is greater at the peaks than it is in the troughs, and a fiber mass
that is less at the peaks than it is in the troughs. This can
result from the coarseness of the downstream and/or upstream coarse
support layers 14, 16 relative to the fine fiber filtration layer
12. In particular, as the layers are passed from the first moving
surface to the second moving surface, the relatively fine nature of
the fine fiber filtration layer 12 will allow the downstream and/or
upstream coarse support layers 14, 16 to conform around the waves
formed in the fine fiber filtration layer 12. As the coarse support
layers 14, 16 extend across a peak P, the distance traveled will be
less than the distance that each layer 14, 16 travels to fill a
trough. As a result, the coarse support layers 14, 16 will compact
at the peaks, thus having an increased fiber density at the peaks
as compared to the troughs, through which the layers will travel to
form a loop-shaped configuration.
[0062] Once the layers are formed into a waved configuration, the
waved shape can be maintained by activating the binder fibers to
effect bonding of the fibers. A variety of techniques can be used
to activate the binder fibers. For example, if bicomponent binder
fibers having a core and sheath are used, the binder fibers can be
activated upon the application of heat. If monocomponent binder
fibers are used, the binder fibers can be activated upon the
application of heat, steam and/or some other form of warm moisture.
A top layer 18 (FIG. 1A) and/or bottom layer 18B (FIG. 1B) can also
be positioned on top of the upstream coarse support layer 16 (FIG.
1A) or on the bottom of the downstream coarse support layer 14B
(FIG. 1B), respectively, and mated, such as by bonding, to the
upstream coarse support layer 16 or downstream coarse support layer
14B simultaneously or subsequently. A person skilled in the art
will also appreciate that the layers can optionally be mated to one
another using various techniques other than using binder fibers.
Other suitable mating techniques include adhesives, needling,
hydroentanglement, and chemical binders. The layers can also be
individually bonded layers, and/or they can be mated, including
bonded, to one another prior to being waved.
[0063] A saturant can also optionally be applied to the material
prior to drying the material. A variety of saturants can be used
with the media of the present invention to facilitate the forming
of the layers at a temperature that is less than the melting
temperature of the fibers. Exemplary saturants can include phenolic
resins, melamine resins, urea resins, epoxy resins, polyacrylate
esters, polystyrene/acrylates, polyvinyl chlorides,
polyethylene/vinyl chlorides, polyvinyl acetates, polyvinyl
alcohols, and combinations and copolymers thereof that are present
in an aqueous or organic solvent.
[0064] In other embodiments, the resulting media can also have a
gradient in at least one, and optionally all, of the following
properties: binder and non-binder fibers composition, fiber
diameter, solidity, basis weight, and saturant content. For
example, in one embodiment, the media can have a lightweight,
lofty, coarse-fibered, lightly bonded and lightly saturated sheet
upstream, and a heavier, denser, fine-fibered, heavily bonded and
heavily saturated sheet downstream. This allows the coarser
particles to be trapped in the upstream layer, preventing early
saturation of the bottom layer. In other embodiments, the
upstream-most layer can be lighter and/or loftier than the
downstream-most layer. That is, the upstream layer can have a
solidity (e.g., the solid volume fraction of fibers in the web) and
a basis weight that is less than that of the downstream layer.
Additionally, in embodiments where the filter media includes a
saturant, the media can have a gradient with respect to the amount
of saturant in the upstream-most and downstream-most layers. One
skilled in the art will appreciate the variety of properties that
the layers of the media can have.
[0065] An electrostatic charge can also optionally be imparted to
the filter media, or to various layers of the media, to form an
electret fiber web. A variety of techniques are well known to
impart a permanent dipole to the polymer web in order to form
electret filter media. Charging can be effected through the use of
AC and/or DC corona discharge units and combinations thereof. The
particular characteristics of the discharge are determined by the
shape of the electrodes, the polarity, the size of the gap, and the
gas or gas mixture. Charging can also be accomplished using other
techniques, including friction-based charging techniques.
[0066] The filter media can also be pleated after it is formed into
the waved configuration, and various exemplary configurations will
be discussed in more detail below. A person skilled in the art will
appreciate that virtually any pleating technique known in the art
can be used to pleat the waved filter media. Typically, a filter
media is pleated by forming a plurality of parallel score lines in
the media and forming folds at each score line.
[0067] Filter Media Properties
[0068] As indicated above, the properties of the resulting filter
media can vary depending on the configuration of the media and the
intended use. In an exemplary embodiment, the waved configuration
is effective to increase the surface area of the media 10, which in
turn results in the media having improved filtration properties
than an otherwise similar media that has a planar
configuration.
[0069] While filter performance can be evaluated based on different
criteria, it is desirable that filters, or filter media, be
characterized by low penetration across the filter of contaminants
to be filtered. At the same time, however, there should exist a
relatively low pressure drop, or resistance, across the filter.
Penetration, often expressed as a percentage, is defined as
follows:
Pen=C/C.sub.0
where C is the particle concentration after passage through the
filter and C.sub.0 is the particle concentration before passage
through the filter. Filter efficiency is defined as
100-% Penetration.
[0070] Because it is desirable for effective filters to maintain
values as low as possible for both penetration and pressure drop
across the filter, filters are rated according to a value termed
alpha, which is the slope of log penetration versus pressure drop
across the filter. Steeper slopes, or higher alpha values, are
indicative of better filter performance. Alpha is expressed
according to the following formula
Alpha=-100 log(C/C.sub.0)/DP,
where DP is the pressure drop across the filter media.
[0071] In many filtering situations it is important to have a high
initial alpha value. However, it is equally, if not more important,
to maintain acceptable alpha values well into the filtration
process. For example, in respiratory applications, manufacturing
standards mandate that the final respiratory filter, such as a
respiratory mask, be subjected to elevated temperatures to simulate
an aged effect. Accordingly, the filter media must be capable of
maintaining a high alpha value when subjected to heat.
[0072] In certain applications, such as HVAC, discharged
performance is also important. Synthetic filter media are often
charged in order to enhance the filtration performance. Due to
concerns that this charge will dissipate during the use of the
filter, there is a movement to inform users of a filter's worst
possible efficiency. EN779:2002, the European standard for coarse
and fine filters, contains a mandatory test on flat piece media
before and after discharging to determine whether there is a
potential for performance degradation. The test method can be used
with any procedure that results in a completely discharge media.
Procedures suggested include immersion in isopropanol or
surfactants in water or exposure to diesel fumes. Treatment with
isopropanol is performed by first measuring the efficiency of
untreated media samples. Next, the samples are immersed in a 100%
solution of isopropanol, and after the filter samples have been
wetted by isopropanol they are placed on a flat, inert surface in a
fume cupboard for drying. After a drying period of 24 hours, the
efficiency measurements are repeated.
[0073] The DOP (dioctyl phthalate) challenge employs an automated
filter testing unit (8130) purchased from TSI, Inc. equipped with
an oil generator. The instrument measures pressure drop across
filter media and the resultant penetration value on an
instantaneous or "loading" basis at a flow rate less than or equal
to 115 liters per minute. Instantaneous readings are defined as 1
pressure drop/penetration measurement. According to TSI
specifications, the oil generator produces a 0.33 micron mass mean
diameter 0.20 micron count mean diameter with DOP, DEHS paraffin,
or Emory 3004. All references herein to DOP alpha refer to a DOP
challenge applied to a sample size of 100 cm.sup.2. The air flow
rate was 32 lpm to produce a 10.5 fpm face velocity or 76 lpm to
produce a 25 fpm face velocity.
[0074] Another exemplary test is the NaCl (sodium chloride)
challenge, which employs an 8130 CertiTest.TM. automated filter
testing unit from TSI, Inc. equipped with a sodium chloride
generator. The average particle size created by the salt particle
generator is 0.26 micron mass mean diameter or 0.07 micron count
mean diameter. The instrument measures a pressure drop across the
filter media and the resultant penetration value on an
instantaneous basis at a flow rate less than or equal to 115 liters
per minute (lpm). The 8130 can be run in a continuous mode with one
pressure drop/penetration reading approximately every minute. All
references herein to NaCl alpha refer to a continuous loading of
NaCl particles, to represent fine particle loading of a filter,
onto a 100 cm.sup.2 sample at a flow rate of 76 lpm (face velocity
of 25 fpm). The sample was loaded for a period of 60 minutes at a
concentration of 15 mg NaCl/m.sup.3 air for a loading of
approximately 60 mg NaCl per 100 cm.sup.2 sample.
[0075] Glass media which meets EN779 classification of F5 to F8 is
found to have an alpha value in the range of about 12 to 16 with
DOP or DEHS (dioctyl sebacate, an accepted equivalent to DOP) when
tested at a face velocity of 5.3 cm/s before and after discharging
using isopropyl alcohol, as explained above. The media of the
present invention achieves a minimum DOP alpha of 9, and more
preferably greater than about 11, and most preferably greater than
16, after discharging using isopropyl alcohol, thus providing a
suitable alternative to glass media. For a DOP alpha of 9, the
equivalent NaCl alpha after IPA soak is about 12, for a DOP alpha
of 11, the equivalent NaCl alpha after IPA soak is about 14, and
for a DOP alpha of 16 the equivalent NaCl alpha after IPA soak is
about 20. However, the alpha value of the filter media in
accordance with the present invention may vary depending on the
particular configuration of the filter media, or the filter element
containing the filter media.
[0076] MERV (Minimum Efficiency Reporting Value) ratings are used
by the HVAC (Heating, Ventilating and Air Conditioning) industry to
describe a filter's ability to remove particulates from the air.
The MERV rating is derived from the efficiency of the filter versus
particles in various size ranges, and is calculated according to
methods detailed in ASHRAE 52.2. A higher MERV rating means better
filtration and greater performance. In an exemplary embodiment,
filter media according to the present invention have a MERV rating
that is in the range of about 7 to 16, however the rating can vary
based on the intended use.
[0077] The resulting media can also have a variety of thicknesses,
air permeabilities, basis weights, and dust holding capacities
depending upon the requirements of a desired application.
Thickness, as referred to herein, is determined according to TAPPI
T411 using an appropriate caliper gage. Basis weight, as referred
to herein, is determined according to ASTM D-846. The dust holding
capacity, as referred to herein, is tested based on a modification
to ASHRAE 52.1 to test dust loading on flat sheet instead of bag.
The pressure drop across a 1 ft.sup.2 sample is measured at a face
velocity of 25 fpm. ASHRAE dust as specified in ASHRAE 52.1 is
added in 1 gram increments until a pressure drop of 1.5 inch
H.sub.2O is reached. The number of grams to get to this pressure
drop is noted in gram/ft.sup.2.
[0078] For example, in one embodiment, the resulting media can have
a thickness t.sub.m, as shown in FIG. 1A, in the range of about 1.5
mm to 25 mm, and an air permeability in the range of about 10 CFM
to 300 CFM. The resulting media can also have a basis weight in the
range of about 70 gsm to 1100 gsm, a dust holding capacity of at
least about 8 g/ft.sup.2@25 FPM face velocity using ASHRAE dust
loading to 1.5'' H.sub.20 pressure drop, and/or a NaCl loading of
less than about 50 mm H.sub.2O after loading approximately 60
mg/100 cm.sup.2 of 0.26.mu. particles at 25 FPM face velocity.
[0079] Filter Elements
[0080] As previously indicated, the filter media disclosed herein
can be incorporated into a variety of filter elements for use in
various applications, including both liquid and air filtration
applications. Exemplary uses include ASHRAE bag filters, pleatable
HVAC filters, liquid bag filter media, dust bag house filters,
residential furnace filters, paint spray booth filters, surgical
face masks, industrial face masks, cabin air filters, commercial
ASHRAE filters, respirator filters, automotive air intake filters,
automotive fuel filters, automotive lube filters, room air cleaner
filters and vacuum cleaner exhaust filters. The filter elements can
have various configurations, and certain exemplary filter element
configurations are discussed in more detail below. Other exemplary
filter elements include, by way of non-limiting example, radial
filter elements that include cylindrical filter media disposed
therein, micron-rater vessel bag filters (also referred to as sock
filters) for liquid filtration, face masks, etc.
[0081] Panel Filter
[0082] In one exemplary embodiment, the filter media can be used in
a panel filter. In particular, the filter media 10 can include a
housing disposed therearound. The housing can have various
configurations, and the particular configuration can vary based on
the intended application. In one embodiment, as shown in FIG. 2A,
the housing is in the form of a frame 20 that is disposed around
the perimeter of the filter media 10. In the illustrated
embodiment, the frame 20 has a generally rectangular configuration
such that it surrounds all four sides of a generally rectangular
filter media 10, however the particular shape can vary. The frame
20 can be formed from various materials, including cardboard,
metal, polymers, etc. In certain exemplary embodiments, the frame
20 can have a thickness t that is about 12'' or less, and more
preferably about 2'' or less. FIG. 2B illustrates a side
cross-sectional view of the frame showing the waved filter media 10
disposed therein. In another embodiment, the frame can be formed
from the edges of the filter media. In particular, as shown in FIG.
3, a perimeter of the filter media 10' can be thermally sealed to
form a frame 20' therearound. The panel filter can also include a
variety of other features known in the art, such as stabilizing
features for stabilizing the filter media relative to the frame,
spacers, etc.
[0083] In use, the panel filter element can be used in a variety of
applications, including commercial and residential HVAC; automotive
passenger cabin air; automotive air intake; and paint spray booth
filters. The particular properties of the filter element can vary
based on the intended use, but in certain exemplary embodiments,
the filter element has a MERV rating in the range of 7 to 16, and a
pressure drop in the range of about 0.1'' to 1'' H.sub.2O.
[0084] Pleated Filter
[0085] The waved filter media can also be pleated and used in a
pleated filter. As previously discussed, the waved media, or
various layers thereof, can be pleated by forming score lines at a
predetermined distance apart from one another, and folding the
media. A person skilled in the art will appreciate, however, that
other pleating techniques can be used. Once the media is pleated,
the media can be incorporated into a housing, similar to the panel
filter of FIG. 3A. FIG. 4A illustrates one embodiment of a pleated
filter media 32 that is disposed within a frame 30. The frame can
have various shapes and sizes, as previously discussed with respect
to FIG. 3A. The media can have any number of pleats depending on
the size of the frame and the intended use. In certain exemplary
embodiment, the filter media has 1-2 pleats per inch, and a pleat
height in the range of about 0.75'' to 2''. However, some
applications utilize peaks having a height up to 12''.
[0086] In order to facilitate pleating, the filter media can be
self-supporting, i.e., it can have a stiffness that allows
pleating. In certain exemplary embodiments, the minimum stiffness
of the filter media is about 200 mg with Gurley Stiffness tester to
enable pleating. Alternatively, or in addition, the filter media
can include various stiffening elements. By way of non-limiting
example, FIGS. 4B and 4C illustrate a waved filter media 32a, 32b
that is pleated, and that includes a stabilizing strap 34a, 34b
that is adhered to (e.g., using an adhesive or other bonding
techniques) an air outflow side of the filter media 32a, 32b. The
filter media 32a, 32b are also shown disposed within a frame 30a,
30b. FIG. 4B further illustrates a screen backing 36a disposed on
the filter media 32a to stiffen the media 32a and help retain the
pleated configuration. The screen backing 36a can be an expanded
metal wire or an extruded plastic mesh.
[0087] In use, the pleated waved filter element can be used in a
variety of applications, including pleatable HVAC filters,
residential furnace filters, cabin air filters, commercial ASHRAE
filters, automotive air intake filters, automotive fuel filters,
automotive lube filters, room air cleaner filters, and vacuum
cleaner exhaust filters. The particular properties of the filter
element can vary based on the intended use, but in certain
exemplary embodiments, the filter element has a MERV rating in the
range of 7 to 16, a pressure drop in the range of about 0.1'' to
1'' inch H.sub.2O. The filter media can also have a thickness
before pleating of about 0.5'' of less, and a thickness after
pleating of about 2'' or less. However, in certain application the
thickness after pleating can be up to 12''.
[0088] Bag/Pocket Filter
[0089] In yet another embodiment, the filter media can be
incorporated into a bag or pocket filter for use in heating, air
conditioning, ventilation, and/or refrigeration; and micron rated
liquid filter bags. The bag or pocket filter can be formed by
placing two filter media together (or folding a single filter media
in half), and mating three sides (or two if folded) to one another
such that only one side remains opens, thereby forming a pocket
inside the filter. As shown in FIG. 5A, multiple filter pockets 42
can be attached to a frame 44 to form a filter element 40. Each
pocket 42 can be positioned such that the open end is located in
the frame, thus allowing air to flow into each pocket 42 in the
direction indicated by line A. The frame can include rectangular
rings that extend into and retain each pocket. A person skilled in
the art will appreciate that the frame can have virtually any
configuration, and various mating techniques known in the art can
be used to couple the pockets to the frame. Moreover, the frame can
include any number of pockets, but bag filters typically include
between 6 and 10 pockets.
[0090] FIG. 5B illustrates one pocket 42 showing three edges 42a,
42b, 42c being closed and one edge 42d being open for receiving
airflow therethrough, as indicated by line A. As further shown in
FIG. 5B, the pocket filter 42 can also include any number of
spacers 43 disposed therein and configured to retain opposed
sidewalls of the filter 42 at a predetermined distance apart from
one another. The spacers can be threads or any other element
extending between both sidewalls. FIG. 5C illustrates a
cross-sectional view of the pocket filter 42 of FIG. 5B, showing
the spacer 43 extending between the sidewalls. The direction of
airflow is again indicated by line A. A person skilled in the art
will appreciate that various features known in the art for use with
bag or pocket filters can be incorporated into the filter media
disclosed herein.
[0091] The particular properties of the filter element can vary
based on the intended use, but in certain exemplary embodiments,
the filter element has a MERV rating in the range of about 7 to 16,
and more preferably 10 to 16, and a pressure drop in the range of
about 0.1'' to 1'' H.sub.2O. The filter media can also have a
thickness that is about 2'' or less, and more preferably about
0.5'' or less, however the thickness can vary depending on the
intended application.
[0092] By way of non-limiting example, a standard 8 pocket ASHRAE
bag filter typically has a 30'' deep pocket in a 24''.times.24''
frame, and yields 80 sq. ft. of media. An ASHRAE bag filter having
the same dimensions, but utilizing a waved filter media according
to the present invention, will yield 176 sq. ft. of media.
[0093] The following non-limiting examples serve to further
illustrate the present invention:
Example 1
Comparative Sample A (Control)
[0094] Sample A is a planar filter media that is manufactured by
Johns Manville and sold as CM285B-2, and it is an 80-85% glass mat
filter media. The properties of the media were tested and are
listed below in Table 1 under Sample A.
[0095] For all samples, the DOP Penetration and DOP alpha were
measured after discharging the media using isopropyl alcohol. In
particular, the sample was placed in a container containing a 100%
isopropyl alcohol solution, and allowed to soak for approximately 5
seconds or until full saturation was achieved. The sample was then
removed from the solution and allowed to drain for approximately 30
seconds. The sample was then placed in a fume/vacuum hood and
allowed to air dry. Drying time was greatly dependent upon the
thickness of the sample, and varied from 20 minutes to 48 hours.
The DOP Penetration and DOP alpha tests were then performed.
Comparative Sample B (Control)
[0096] Sample B is a planar filter media that is manufactured by
Hollingsworth & Vose Company and sold as AS8020DD, and it is
80-85% synthetic filter media. The properties of the media were
tested and are listed below in Table 1 under Sample B.
Sample C
[0097] Sample C was formed using four layers, listed in order from
upstream (air entry) to downstream (air outflow): (1) a top airlaid
layer, (2) an upstream airlaid coarse support layer, (3) a fine
fiber meltblown layer, and (4) a downstream airlaid coarse support
layer.
[0098] The top airlaid layer was formed from 50% of a 2 denier by 6
mm Type 255 bicomponent fiber available from Invista, and 50% of a
0.9 denier by 6 mm Type 510 polyethyleneterephthalate (PET) fiber
available from Wellman. The top airlaid layer was bonded in an
oven. The top airlaid layer had a basis weight of 25 gsm, a
thickness of 30 mil, and an air permeability of 850 CFM.
[0099] The upstream airlaid coarse support layer was formed from
70% of a 2 denier by 6 mm Type 255 bicomponent fiber available from
Invista, 20% of a 0.9 denier by 6 mm Type 510 PET fiber available
from Wellman, and 10% of a 15 denier by 6 mm Type 341 PET fiber
available from Wellman. The upstream airlaid coarse support layer
had a basis weight of 40 gsm, a thickness of 40 mil, and an air
permeability of 800 CFM.
[0100] The fine fiber meltblown layer was formed from a
polypropylene fiber having an average fiber diameter of 1.4.mu..
The basis weight of the meltblown layer was 20 gsm, the thickness
was 7 mil, and the air permeability was 56 CFM.
[0101] The downstream airlaid coarse support layer was formed from
50% of a 2 denier by 6 mm Type 255 fiber available from Invista,
and 50% of a 15 denier by 6 mm Type 341 PET fiber available from
Wellman. The downstream airlaid coarse support layer had a basis
weight of 40 gsm, a thickness of 40 mil, and an air permeability of
2000 CFM.
[0102] The upstream coarse support layer, the fine fiber meltblown
layer, and the downstream coarse support layer were formed into a
waved configuration by placing the layers on a first moving surface
traveling at a speed of about 25 m/min. The layers traveled from
the first moving surface to a second moving surface traveling at a
speed of about 10 m/min, and as a result 4 waves per inch were
formed. The waved webs and the top layer were then thermally bonded
in an oven at 130.degree. C. The properties of the resulting media
were tested and are listed below in Table 1 under Sample C.
Sample D
[0103] Sample C was repeated to form Sample D, however the fine
fiber meltblown layer was formed from a polypropylene fiber having
an average fiber diameter of 0.6.mu. on a 10 gsm polypropylene
spunbond. The basis weight of the meltblown layer was 7 gsm. The
properties of the resulting media were tested and are listed below
in Table 1 under Sample D.
Sample E
[0104] Sample C was repeated to form Sample E. The properties of
the resulting media were tested and are listed below in Table 1
under Sample E.
TABLE-US-00001 TABLE 1 Sample A Sample B Sample C Sample D Sample E
Total Basis Weight (gsm) 71 125 245 245 256 Thickness (mil) 60 65
283 308 275 Air Permeability (CFM) 61 130 71 97 67 Resistance
(mmH.sub.2O) @ 10.5 2.3 1.1 2.7 1.7 2.5 FPM Resistance (mmH.sub.2O)
@ 25 FPM 6 5 6.7 4.4 5.6 DOP Penetration (%) at 10.5 48 88 45 52 46
FPM after IPA soak DOP alpha at 10.5 FPM after 13.9 5.0 12.8 16.7
13.5 IPA soak Dust Holding Capacity (g/ft.sup.2 @ 7.7 5.9 12.3 11.5
10.3 25 FPM to 1.5'' H.sub.2O)
[0105] As shown in Table 1, Samples C, D, and E have improved dust
holding capacities and higher or equivalent DOP alpha after
discharge using isopropyl alcohol as compared to Samples A and B.
The various properties of Samples A-E are compared in graphs set
forth in FIGS. 6-9.
[0106] FIG. 6 illustrates the discharged DOP Penetration versus the
pressure drop. As shown, Sample B has a high initial pressure drop
which decreases significantly as the penetration increases. Samples
A, C, D, and E, on the other hand, have a low initial pressure drop
that decreases slowly as the penetration increases. Thus, Samples
C, D, and E have properties that are comparable to Sample A, which
is a glass fiber mat, and that are superior to Sample B, which is a
meltblown web. FIG. 6 therefore illustrates that the waved
configuration of Samples C, D, and E advantageously improve the
pressure drop as a function of penetration, and thus provide a
suitable alternative to glass mat fiber webs.
[0107] FIG. 7 illustrates the dust holding capacity of Samples A-E.
As shown, Samples A and B show a significantly lower dust holding
capacity as compared to Samples C, D, and E. Thus, the waved
configuration of Samples C, D, and E results in an improved dust
holding capacity as compared to the planar configuration of Samples
A and B.
Example 2
[0108] A first planar fine fiber meltblown layer, referred to as
Meltblown C, was prepared having the same configuration as the fine
fiber meltblown layer of Sample C. The basis weight of Meltblown C
was 20 gsm.
[0109] A second planar fine fiber meltblown layer, referred to as
Meltblown D, was prepared having the same configuration as the fine
fiber meltblown layer of Sample D. The basis weight of Meltblown D
was 20 gsm.
[0110] The NaCl loading for Meltblown C and Meltblown D, as well as
for Samples C and D from Example 1 above, were tested and the NaCl
Loading at 76 lpm is shown in FIG. 8. As shown, the waved filter
media of Samples C and D show a significant improvement in NaCl
loading, as the resistance remains low over a longer period of
time, as compared to Meltblown C and Meltblown D.
Example 3
Comparative Sample F
[0111] Sample F was formed using four layers, listed in order from
upstream (air entry) to downstream (air outflow): (1) a top carded
nonwoven layer, (2) a fine fiber meltblown layer, and (3) a
downstream carded nonwoven layer.
[0112] The top and bottom nonwoven layers were formed from 45% of a
3 denier by 1.75'' Type 202 bicomponent fiber available from FIT,
and 30% of a 3 denier by 2'' Type N39 PET fiber available from
Poole. The top and bottom nonwoven layers were each bonded in an
oven. The top and bottom nonwoven layers each had a basis weight of
160 gsm, a thickness of 155 mil, and an air permeability of 420
CFM.
[0113] The fine fiber meltblown layer was formed from a
polypropylene fiber having an average fiber diameter of 1.1.mu..
The basis weight of the meltblown layer was 35 gsm, the thickness
was 11 mil, and the air permeability was 39 CFM.
[0114] The top and bottom nonwoven layers were positioned on
opposite sides of the fine fiber meltblown layer to form a planar
filter media. The properties of the resulting media were tested and
are listed below in Table 1 under Sample F.
Sample G
[0115] Sample G was formed using four layers, listed in order from
upstream (air entry) to downstream (air outflow): (1) a top airlaid
layer, (2) an upstream airlaid coarse support layer, (3) a fine
fiber meltblown layer, and (4) a downstream airlaid coarse support
layer.
[0116] The top airlaid layer was formed from 50% of a 2 denier by 6
mm Type 255 bicomponent fiber available from Invista, and 50% of a
0.9 denier by 6 mm Type 510 polyethylene terephthalate (PET) fiber
available from Wellman. The top airlaid layer was bonded in an
oven. The top airlaid layer had a basis weight of 25 gsm, a
thickness of 40 mil, and an air permeability of 850 CFM.
[0117] The upstream airlaid coarse support layer was formed from
70% of a 2 denier by 6 mm Type 255 bicomponent fiber available from
Invista, 20% of a 0.9 denier by 6 mm Type 510 PET fiber available
from Wellman, and 10% of a 15 denier by 6 mm Type 341PET fiber
available from Wellman. The upstream airlaid coarse support layer
had a basis weight of 40 gsm, a thickness of 40 mil, and an air
permeability of 800 CFM.
[0118] The fine fiber meltblown layer was formed to correspond to
the fine fiber meltblown layer of Sample F. In particular, the fine
fiber meltblown layer was formed from a polypropylene fiber having
an average fiber diameter of 1.1.mu.. The basis weight of the
meltblown layer was 35 gsm, the thickness was 11 mil, and the air
permeability was 39 CFM.
[0119] The downstream airlaid coarse support layer was formed from
50% of a 2 denier by 6 mm Type 255 fiber available from Invista,
and 50% of a 15 denier by 6 mm Type 341 PET fiber available from
Wellman. The downstream airlaid coarse support layer had a basis
weight of 38 gsm, a thickness of 40 mil, and an air permeability of
2000 CFM.
[0120] The upstream coarse support layer, the fine fiber meltblown
layer, and the downstream coarse support layer were formed into a
waved configuration by placing the layers on a first moving surface
traveling at a speed of about 25 m/min. The layers traveled from
the first moving surface to a second moving surface traveling at a
speed of about 10 m/min, and as a result 4 waves per inch were
formed. The waved webs and the top layer were then thermally bonded
in an oven at 140.degree. C. The properties of the resulting media
were tested and are listed below in Table 2 under Sample G.
TABLE-US-00002 TABLE 2 Sample F Sample G Total Basis Weight (gsm)
350 259 Total Thickness (mil) 330 269 Air Permeability (CFM) 34.2
38.8 Caliper (mm) 6.79 4.6 Capacity (g/m.sup.2) 128.03 324.22 Test
Time (minutes) 33.81 85.27 Beta75 15.8 7.6
[0121] As shown in Table 2, waved Sample G has a lower Beta.sub.75
than planar Sample F. Beta.sub.75 is determined by ISO 16889. Using
a FTI Multipass Filter Test Stand available from Fluid Technologies
Inc., of Stillwater, Okla., an A2 fine dust is fed at a rate of 0.3
liters per minute into Mobil MIL-H-5606 fuel for a total flow rate
of 1.7 liters per minute until a terminal pressure of 172 KPa above
the baseline filter pressure drop is obtained. Particle counts
(particles per milliliter) at the particle sized selected (in this
case 4, 5, 7, 10, 15, 20, 25, and 30 microns) upstream and
downstream of the media are taken at ten points equally divided
over the time of the test. The average of upstream and downstream
particle counts are taken at each selected particle size. From the
average particle count upstream (injected-C.sub.0) and the average
particle count downstream (passed thru-C) the liquid filtration
efficiency test value for each particle size selected is determined
by the relationship [(100-[C/C.sub.0])*100%]. Another expression of
efficiency is Beta Rating. Beta.sub.75 is defined as the particle
size where the ratio of the upstream count (C.sub.0) to downstream
count (C) equals 75 (efficiency equals 98.67%). The lower the Beta
Rating, the lower the particle size for an efficiency. Generally,
efficiency decreases as the particle size decreases.
[0122] FIG. 9 illustrates the pressure of Samples F and G as a
function of time, as tested using a multi-pass test for liquid
filtration per ISO 16889. During such a test, a dust is dispersed
in oil, and the dispersion is passed through the filter media until
a given pressure drop is reached (172 kPa in this test). It is more
desirable to have the pressure increase over a longer period of
time. As shown in FIG. 9, Sample G loads in 85 minutes while the
comparable flat sheet of Sample F loads in 34 minutes.
Example 4
Sample H
[0123] Sample H was formed using four layers, listed in order from
upstream (air entry) to downstream (air outflow): (1) an upstream
carded fiber coarse support layer, (2) a fine fiber meltblown
layer, (3) a downstream carded fiber coarse support layer, and (4)
a bottom spunbond layer.
[0124] The upstream carded fiber coarse support layer was formed
from 70% of a 2 denier by 1.5 inch Type 256 bicomponent fiber
available from Trevira and 30% of a 3 denier by 2 inch Type P320
PET fiber available from Barnet. The upstream carded fiber coarse
support layer had a basis weight of 35 gsm, a thickness of 40 mil,
and an air permeability of 800 CFM.
[0125] The fine fiber meltblown layer was formed from a
polypropylene fiber having an average fiber diameter of about
0.7.mu.. The basis weight of the meltblown layer was 15 gsm, the
thickness was 5 mil, and the air permeability was 68 CFM.
[0126] The downstream carded fiber coarse support layer was formed
from 40% of a 2 denier by 1.5 inch Type 256 fiber available from
Trevira, and 60% of a 3 denier by 2 inch Type P320 PET fiber
available from Barnet. The downstream airlaid coarse support layer
had a basis weight of 35 gsm, a thickness of 40 mil, and an air
permeability of 1000 CFM.
[0127] The bottom spunbond layer was a polypropylene spunbond
purchased from Polymer Group, Inc. The bottom spunbond layer had a
basis weight of 15 gsm, a thickness of 3 mil, and an air
permeability of 1200 CFM.
[0128] The upstream coarse support layer, the fine fiber meltblown
layer, and the downstream coarse support layer were formed into a
waved configuration by placing the layers on a first moving surface
traveling at a speed of about 10 m/min. The layers traveled from
the first moving surface to a second moving surface traveling at a
speed of about 4 m/min, and as a result 3 waves per inch were
formed. The waved webs and the bottom spunbond layer were then
thermally bonded in an oven at 130.degree. C. The properties of the
resulting media were tested and are listed below in Table 3 under
Sample H.
Sample I
[0129] Sample G was repeated for Sample I, however a bonded, carded
fiber layer was used in place of the bottom spunbond layer. The
bottom carded fiber layer was formed from 50% of a 2 denier by 1.5
inch Type 256 bicomponent fiber available from Trevira, and 50% of
a 0.9 denier by 1.5 inch Type P1842B polyethyleneterephthalate
(PET) fiber available from Barnet. The bottom carded fiber layer
was pre-bonded in an oven at 130.degree. C. The top airlaid layer
had a basis weight of 25 gsm, a thickness of 20 mil, and an air
permeability of 890 CFM. The properties of the resulting media were
tested and are listed below in Table 3 under Sample I.
TABLE-US-00003 TABLE 3 Physical Property Sample G Sample I
Coverstock (SB/NW) Spunbond Nonwoven Basis Weight (g/m.sup.2) 206.1
228.78 Caliper (mils) 234 457.63 Air Permeability (CFM) 81 80
Initial Values: Airflow Resistance @ 32 lpm; 100 cm.sup.2 (mm
H.sub.2O) 2.14 2.10 Airflow Resistance @ 76 lpm; 100 cm.sup.2 (mm
H.sub.2O) 5.54 5.29 NaCl Penetration @ 32 lpm; 100 cm.sup.2 (%)
39.7 34.7 NaCl Penetration @ 76 lpm; 100 cm.sup.2 (%) 45.6 42.7
NaCl Alpha @ 32 lpm; 100 cm.sup.2 (mm H.sub.2O.sup.-1) 18.8 21.9
NaCl Alpha @ 76 lpm; 100 cm.sup.2 (mm H.sub.2O.sup.-1) 6.2 7.0 DOP
Penetration @ 32 lpm; 100 cm.sup.2 (%) 47.8 44.1 DOP Penetration @
76 lpm; 100 cm.sup.2 (%) 52.4 48.7 DOP Alpha @ 32 lpm; 100 cm.sup.2
(mm H.sub.2O.sup.-1) 15.0 16.9 DOP Alpha @ 76 lpm; 100 cm.sup.2 (mm
H.sub.2O.sup.-1) 5.1 5.9 After IPA Discharge: Airflow Resistance @
32 lpm; 100 cm.sup.2 (mm H.sub.2O) 2.12 2.03 Airflow Resistance @
76 lpm; 100 cm.sup.2 (mm H.sub.2O) 5.32 5.41 NaCl Penetration @ 32
lpm; 100 cm.sup.2 (%) 39.4 34.4 NaCl Penetration @ 76 lpm; 100
cm.sup.2 (%) 45.7 39.1 NaCl Alpha @ 32 lpm; 100 cm.sup.2 (mm
H.sub.2O.sup.-1) 19.1 22.8 NaCl Alpha @ 76 lpm; 100 cm.sup.2 (mm
H.sub.2O.sup.-1) 6.4 7.5 DOP Penetration @ 32 lpm; 100 cm.sup.2 (%)
47.5 42.6 DOP Penetration @ 76 lpm; 100 cm.sup.2 (%) 52.7 47.7 DOP
Alpha @ 32 lpm; 100 cm.sup.2 (mm H.sub.2O.sup.-1) 15.2 18.3 DOP
Alpha @ 76 lpm; 100 cm.sup.2 (mm H.sub.2O.sup.-1) 5.2 6.0 Dust
Holding Value (25 fpm to 1.5'' H.sub.2O) (grams/ 10.3 11.0
ft.sup.2)
Example 5
Sample J
[0130] Sample G was repeated for Sample J, however the fine fiber
meltblown layer was a 6 gsm, 0.7.mu. polypropylene meltblown. The
fine fiber meltblown layer had a thickness of 2.4 mil and an air
permeability of 167 CFM. The properties of the resulting media were
tested and are listed below in Table 4 under Sample J.
Sample K
[0131] Sample G was repeated for Sample K however the fine fiber
meltblown layer was a 22 gsm, 0.7.mu. polypropylene meltblown. The
fine fiber meltblown layer had a thickness of 6.8 mil and an air
permeability of 37 CFM. The properties of the resulting media were
tested and are listed below in Table 4 under Sample K.
TABLE-US-00004 TABLE 4 Physical Property Sample G Sample I
Coverstock (SB/NW) Spunbond Spunbond Basis Weight (g/m.sup.2) 192.4
206.1 Caliper (mils) 215 224 Air Permeability (CFM) 110 48 Initial
Values: Airflow Resistance @ 32 lpm; 100 cm.sup.2 (mm H.sub.2O)
1.36 3.23 Airflow Resistance @ 76 lpm; 100 cm.sup.2 (mm H.sub.2O)
3.64 8.12 NaCl Penetration @ 32 lpm; 100 cm.sup.2 (%) 58.8 27.6
NaCl Penetration @ 76 lpm; 100 cm.sup.2 (%) 63.8 34.8 NaCl Alpha @
32 lpm; 100 cm.sup.2 (mm H.sub.2O.sup.-1) 17.0 17.3 NaCl Alpha @ 76
lpm; 100 cm.sup.2 (mm H.sub.2O.sup.-1) 5.4 5.6 DOP Penetration @ 32
lpm; 100 cm.sup.2 (%) 65.9 33.8 DOP Penetration @ 76 lpm; 100
cm.sup.2 (%) 71.2 40.5 DOP Alpha @ 32 lpm; 100 cm.sup.2 (mm
H.sub.2O.sup.-1) 13.3 14.6 DOP Alpha @ 76 lpm; 100 cm.sup.2 (mm
H.sub.2O.sup.-1) 4.1 4.8 After IPA Discharge: Airflow Resistance @
32 lpm; 100 cm.sup.2 (mm H.sub.2O) 1.32 3.25 Airflow Resistance @
76 lpm; 100 cm.sup.2 (mm H.sub.2O) 3.62 8.02 NaCl Penetration @ 32
lpm; 100 cm.sup.2 (%) 57.3 26.9 NaCl Penetration @ 76 lpm; 100
cm.sup.2 (%) 62.1 34.8 NaCl Alpha @ 32 lpm; 100 cm.sup.2 (mm
H.sub.2O.sup.-1) 18.3 17.5 NaCl Alpha @ 76 lpm; 100 cm.sup.2 (mm
H.sub.2O.sup.-1) 5.7 5.7 DOP Penetration @ 32 lpm; 100 cm.sup.2 (%)
65.5 35.8 DOP Penetration @ 76 lpm; 100 cm.sup.2 (%) 69.8 39.5 DOP
Alpha @ 32 lpm; 100 cm.sup.2 (mm H.sub.2O.sup.-1) 13.92 13.73 DOP
Alpha @ 76 lpm; 100 cm.sup.2 (mm H.sub.2O.sup.-1) 4.31 5.03 Dust
Holding Value (25 fpm to 1.5'' H2O) (grams/ 11.5 8.9 ft.sup.2)
[0132] One skilled in the art will appreciate further features and
advantages of the invention based on the above-described
embodiments. Accordingly, the invention is not to be limited by
what has been particularly shown and described, except as indicated
by the appended claims. All publications and references cited
herein are expressly incorporated herein by reference in their
entirety.
* * * * *